Polycrystalline diamond compacts, and related methods and applications
First Claim
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1. A method of fabricating a leached polycrystalline diamond compact, comprising:
- mixing a plurality of diamond particles with a plurality of sacrificial particles to form a mixture, wherein the plurality of sacrificial particles are present in the mixture in a concentration of greater than 0 to about 5 weight %;
subjecting the mixture to a first high-pressure/high-temperature process having a pressure of about 5 GPa to about 10 GPa and a temperature of about 1300°
C. to about 1600°
C., in the presence of a metal-solvent catalyst comprising a material different from the sacrificial particles, to sinter the mixture and form a polycrystalline diamond table, wherein the polycrystalline diamond table comprises a sacrificial material including the plurality of sacrificial particles, at least one reaction product of the plurality of diamond particles and the plurality of sacrificial particles, or combinations thereof;
leaching at least a portion of the metal-solvent catalyst and at least a portion of the sacrificial material from the polycrystalline diamond table so that the metal-solvent catalyst is present therein in a concentration of less than 0.85 weight %;
positioning the leached polycrystalline diamond table adjacent to a substrate to form an assembly;
subjecting the assembly to a second high-pressure/high-temperature process to at least partially infiltrate the leached polycrystalline diamond table with a metallic infiltrant from at least one of the substrate or an infiltrant layer, wherein the metallic infiltrant includes cobalt; and
at least partially leaching the metallic infiltrant from a region of the infiltrated polycrystalline diamond table.
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Abstract
Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) and methods of fabricating polycrystalline diamond tables and PDCs in a manner that facilitates removal of metal-solvent catalyst used in the manufacture of polycrystalline diamond tables of such PDCs.
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Citations
20 Claims
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1. A method of fabricating a leached polycrystalline diamond compact, comprising:
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mixing a plurality of diamond particles with a plurality of sacrificial particles to form a mixture, wherein the plurality of sacrificial particles are present in the mixture in a concentration of greater than 0 to about 5 weight %; subjecting the mixture to a first high-pressure/high-temperature process having a pressure of about 5 GPa to about 10 GPa and a temperature of about 1300°
C. to about 1600°
C., in the presence of a metal-solvent catalyst comprising a material different from the sacrificial particles, to sinter the mixture and form a polycrystalline diamond table, wherein the polycrystalline diamond table comprises a sacrificial material including the plurality of sacrificial particles, at least one reaction product of the plurality of diamond particles and the plurality of sacrificial particles, or combinations thereof;leaching at least a portion of the metal-solvent catalyst and at least a portion of the sacrificial material from the polycrystalline diamond table so that the metal-solvent catalyst is present therein in a concentration of less than 0.85 weight %; positioning the leached polycrystalline diamond table adjacent to a substrate to form an assembly; subjecting the assembly to a second high-pressure/high-temperature process to at least partially infiltrate the leached polycrystalline diamond table with a metallic infiltrant from at least one of the substrate or an infiltrant layer, wherein the metallic infiltrant includes cobalt; and at least partially leaching the metallic infiltrant from a region of the infiltrated polycrystalline diamond table. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification